Blodgett 40GS-KLS Installation Manual

40GS-KLS Series

GAS SHORT STATIONARY FLOOR KETTLE

INSTALLATION - OPERATION - MAINTENANCE

BLODGETT OVEN COMPANY

www.blodgett.com

44 Lakeside Avenue, Burlington, Vermont 05401 USA

Manufacture Service Questions: 866-518-3977

PART NUMBER 170096 REV A (04/11)

THIS MANUAL MUST BE RETAINED FOR FUTURE REFERENCE. READ, UNDERSTAND AND FOLLOW THE INSTRUCTIONS AND WARNINGS CONTAINED IN THIS MANUAL.

FOR YOUR SAFETY DO NOT STORE OR USE GASOLINE OR OTHER FLAMMABLE VAPORS AND LIQUIDS IN THE VICINITY OF THIS OR ANY OTHER APPLIANCE.

POST IN A PROMINENT LOCATION INSTRUCTIONS TO BE FOLLOWED IN THE EVENT USER SMELLS GAS. THIS INFORMATION SHALL BE OBTAINED BY CONSULTING YOUR LOCAL GAS SUPPLIER. AS A MINIMUM, TURN OFF THE GAS AND CALL YOUR GAS COMPANY AND YOUR AUTHORIZED SERVICE AGENT. EVACUATE ALL PERSONNEL FROM THE AREA.

WARNING IMPROPER INSTALLATION, ADJUSTMENT, ALTERATION, SERVICE OR MAINTENANCE CAN CAUSE PROPERTY DAMAGE, INJURY OR DEATH. READ THE INSTALLATION, OPERATING AND MAINTENANCE INSTRUCTIONS THOROUGHLY BEFORE INSTALLING OR SERVICING THIS EQUIPMENT.

NOTIFY CARRIER OF DAMAGE AT ONCE IT IS THE RESPONSIBILITY OF THE CONSIGNEE TO INSPECT THE CONTAINER UPON RECEIPT OF SAME AND TO DETERMINE THE POSSIBILITY OF ANY DAMAGE, INCLUDING CONCEALED DAMAGE. WE SUGGEST THAT IF YOU ARE SUSPICIOUS OF DAMAGE TO MAKE A NOTATION ON THE DELIVERY RECEIPT. IT WILL BE THE RESPONSIBILITY OF THE CONSIGNEE TO FILE A CLAIM WITH THE CARRIER. WE RECOMMEND THAT YOU DO SO AT ONCE.

IMPORTANT - READ FIRST - IMPORTANT

WARNING: FAILURE TO DISCONNECT POWER BEFORE SERVICING COULD RESULT IN ELECTROCUTION AND

DEATH.

WARNING: THIS UNIT IS INTENDED FOR USE IN THE COMMERCIAL HEATING, COOKING AND HOLDING OF

WATER AND FOOD PRODUCTS, PER THE INSTRUCTIONS CONTAINED IN THIS MANUAL. ANY OTHER USE COULD RESULT IN SERIOUS PERSONAL INJURY OR DAMAGE TO THE EQUIPMENT AND WILL VOID WARRANTY.

WARNING: IMPROPER INSTALLATION, ADJUSTMENT, ALTERATION, SERVICE OR MAINTENANCE CAN

CAUSE PROPERTY DAMAGE, INJURY OR DEATH. READ THE INSTALLATION, OPERATING AND MAINTENANCE INSTRUCTIONS THOROUGHLY BEFORE INSTALLING OR SERVICING THIS EQUIPMENT.

WARNING: THE UNIT MUST BE INSTALLED BY PERSONNEL QUALIFIED TO WORK WITH GAS, ELECTRICITY

AND PLUMBING. UNIT MUST BE INSTALLED IN ACCORDANCE WITH ALL APPLICABLE CODES.

CAUTION: TO AVOID DAMAGING PARTS OF THE BURNER SYSTEM UNDERNEATH THE KETTLE, LIFT THE

UNIT ONLY BY THE RING BENEATH THE OUTER PORTION OF THE BODY.

WARNING: DO NOT ATTACH THE UNIT TO A TYPE “B” VENT. IT COULD CAUSE FIRE OR PROPERTY DAMAGE.

WARNING: DO NOT CONNECT ANY PIPING TO THE PRESSURE RELIEF VALVE. IT MUST BE FREE TO VENT TO

VENT STEAM AS NEEDED. TO AVOID BURNS FROM THE VENTED STEAM THE VALVE DISCHARGE SHOULD POINT DOWN. IMPROPER INSTALLATION WILL VOID WARRANTY.

DANGER: ELECTRICALLY GROUND THE UNIT AT THE TERMINAL PROVIDED. FAILURE TO GROUND THE

UNIT COULD RESULT IN ELECTROCUTION AND DEATH.

CAUTION: BE SURE ALL OPERATORS READ, UNDERSTAND AND FOLLOW THE OPERATING INSTRUCTIONS,

CAUTIONS AND SAFETY INSTRUCTIONS CONTAINED IN THIS MANUAL.

CAUTION: DO NOT OVERFILL THE KETTLE WHEN COOKING, HOLDING OR CLEANING. KEEP LIQUIDS

A MINIMUM OF 2-3” (5-8 CM) BELOW THE KETTLE BODY RIM TO ALLOW CLEARANCE FOR STIRRING, BOILING AND SAFE TRANSFER OF PRODUCT.

CAUTION: KEEP FLOORS IN FRONT OF KETTLE WORK AREA CLEAN AND DRY. IF SPILLS OCCUR, CLEAN

IMMEDIATELY TO AVOID SLIPS OR FALLS.

WARNING: KEEP WATER AND SOLUTIONS OUT OF CONTROLS AND BURNERS. NEVER USE A HIGH

PRESSURE HOSE TO CLEAn THE KETTLE SURFACES.

CAUTION: MOST CLEANERS ARE HARMFUL TO THE SKIN, EYES, MUCOUS MEMBRANES AND CLOTHING.

TAKE PRECAUTIONS: WEAR RUBBER GLOVES, GOGGLES OR FACE SHIELD AND PROTECTIVE CLOTHING. CAREFULLY READ WARNINGS AND FOLLOW DIRECTIONS ON CLEANER LABELS.

IMPORTANT: DO NOT MIX PARTS OF DIFFERENT DRAW-OFF VALVES DURING WASHING. PARTS ARE NOT

INTERCHANGEABLE.

NOTICE: NEVER LEAVE A SANITIZER IN CONTACT WITH STAINLESS STEEL SURFACES LONGER THAN 10

MINUTES. LONGER CONTACT CAN CAUSE CORROSION.

OM-40GS-KLS 1

IMPORTANT - READ FIRST - IMPORTANT

WARNING: FAILURE TO PERIODICALLY CHECK PRESSURE RELIEF VALVE OPERATION COULD RESULT IN

PERSONAL INJURY AND/OR DAMAGE TO EQUIPMENT.

WARNING: WHEN TESTING, AVOID EXPOSURE TO THE STEAM BLOWING OUT OF THE PRESSURE RELIEF

VALVE. DIRECT CONTACT COULD RESULT IN SEVERE BURNS.

WARNING: TO AVOID INJURY, READ AND FOLLOW ALL PRECAUTIONS STATED ON THE LABEL OF THE

WATER TREATMENT COMPOUND.

WARNING: BEFORE REPLACING ANY PARTS, DISCONNECT THE UNIT FROM THE ELECTRIC POWER SUPPLY

AND CLOSE THE MAIN GAS VALVE. ALLOW FIVE MINUTES FOR GAS TO VENT.

CAUTION: USE OF ANY REPLACEMENT PARTS OTHER THAN THOSE SUPPLIED BY THE MANUFACTURER

OR AUTHORIZED DISTRIBUTORS CAN CAUSE INJURY TO THE OPERATOR AND DAMAGE TO THE EQUIPMENT AND WILL VOID ALL WARRANTIES.

WARNING: KEEP AREA AROUND KETTLE FREE AND CLEAR OF ALL COMBUSTIBLE MATERIALS. FAILURE TO

DO SO COULD RESULT IN FIRE OR PROPERTY DAMAGE.

CAUTION: HEATING AN EMPTY KETTLE MAY CAUSE THE RELEASE OF STEAM FROM THE PRESSURE

RELIEF VALVE.

IMPORTANT: SERVICE PERFORMED BY OTHER THAN FACTORY AUTHORIZED PERSONNEL WILL VOID ALL

WARRANTIES.

2 OM-40GS-KLS

Table of Contents

Important Operator Warnings ..................................................... page 1-2

References.................................................................................... page 3

Equipment Description............................................................... page 4-5

Inspection & Unpacking ................................................................. page 6

Installation .................................................................................. page 7-8

Initial Start-Up................................................................................ page 9

Operation ................................................................................ page 10-11

Sequence of Operation ................................................................ page 12

Maintenance............................................................................ page 13-15

Cleaning.................................................................................. page 16-17

Troubleshooting...................................................................... page 18-19

Parts List................................................................................. page 20-24

Electrical Schematic .................................................................... page 25

Service Log ............................................................................. page 26-27

References

CSA International 8501 East Pleasant Valley Road Cleveland, Ohio 44131

NATIONAL SANITATION FOUNDATION 3475 Plymouth Rd. Ann Arbor, Michigan 48106

KLENZADE SALES CENTER ECOLAB. Inc. 370 Wabasha St. Paul, Minnesota 55102

ZEP MANUFACTURING CO. 1310-T Seaboard Industrial Blvd. Atlanta, Georgia 30318

AMERICAN NAT’L STANDARDS INST., INC. 1430 Broadway New York, New York 10018

Z223.1-1984 - National Fuel Gas Code Z21.30 - Installation of Gas Appliances & Piping

NATIONAL FIRE PROTECTION ASSOCIATION 60 Battery March Park Quincy, Massachusetts 02269

NFPA/54 - Installation Gas Appliances & Piping NFPA/70 - The National Electrical Code

OM-40GS-KLS 3

Equipment Description

MODEL Ignition

40GS-KLS Spark

FIRING RATE, BTU/HR

Natural

Gas

115,000 115,000

Propane

Gas

Blodgett 40GS-KLS steam kettles are stainless steel, ﬂoor mounted kettles with a selfcontained steam source heated by gas. A closed steam jacket covers the lower 2/3 of the kettle. Heat from the gas burner boils water in the jacket to produce steam under pressure. To ignite the burners, the kettle uses electronic spark ignition.

The kettles are stationary (non-tilting). Liquids can be removed through the tangent draw-off valve.

Exposed surfaces are stainless steel. Insulated sheathing protects the kettle body, and a housing encloses the controls. Three tubular legs support the unit. Bullet feet adjust to level the kettle.

A one piece dome cover is hinged to the kettle. Covers for 40 gallon kettles are supplied with counterbalancing spring actuators to hold the covers in the fully open or closed position.

Controls provided include the ON/OFF switch, to control electric power for the unit, and the thermostat, to set the cooking temperature. The automatic controls and a brief description of each are as follows.

1. Gas pressure regulator: Protects the unit from high pressure in the gas supply line.

2. Automatic gas valves: Allow gas into the burners as needed.

3. Pressure limit switch: Turns off the burner when jacket pressure reaches 27 PSI. Lights the burner when pressure drops to 22 PSI.

4. Safety valve: Lets steam out of the jacket if the steam pressure exceeds 30 PSI.

5. Low-water cutoff: Turns off the burner if the water level in the jacket gets too low for safe operation.

Instruments also are provided to show what is happening inside the unit. These are:

1. Water level sight glass: Indicates whether there is enough water in the steam jacket.

2. Pressure/vacuum gauge: Shows steam pressure, and whether too much air has entered the jacket.

3. Heating indicator light: Indicates that the kettle is being heated.

4. Power on indicator light: Glows when the unit is turned on.

5. Low water indicator light: Lights to show that jacket water needs to be replenished.

The kettle body is welded into one piece and has a rim reinforced by a rectangular bar. The interior and exterior of the kettle is polished to a 180 emery grit ﬁnish. The unit is ASME shop inspected and registered with the National Board for working pressures up to 30 PSI.

The standard 2 inch tangent draw-off is a 316 stainless steel, compression disc valve. A removable strainer with ¼ inch holes keeps pieces of product from entering the draw-off during cooking.

The jacket is ﬁlled at the factory with water containing rust inhibitors. The kettle can operate at steam pressures up to 30 PSI, which provide temperatures of 150ºF (65ºC) to approximately 250ºF (121ºC). This range allows warming, simmering, boiling, or braising.

4 OM-40GS-KLS

Equipment Description

For kettles, options include:

1. Larger (3 inch) draw-off *

2. Solid disc strainer or strainer with 1/8 inch perforations

3. Water Fill faucet

4. Basket

5. Kettle brush kit

6. Gallon etch marks*

7. Flanged feet

* Factory installed options

Model

40GS-KLS

Kettle

Capacity

40 Gallons

150 liters

Jacket

Capacity

7 Gallons

26.5 liters

Kettle Inside

Diameter

26 inches

660 mm

Kettle Depth

22 inches

559 mm

Overall Width Front-to-Back Rim Height

38-1/4 inches

972 mm

45 inches 1143 mm

38.6 inches 981 mm

OM-40GS-KLS 5

Inspection & Unpacking

WARNING

THIS UNIT MUST BE INSTALLED BY

PERSONNEL WHO ARE QUALIFIED TO

WORK WITH ELECTRICITY AND PLUMBING.

IMPROPER INSTALLATION CAN CAUSE

INJURY TO PERSONNEL AND/OR DAMAGE

TO THE EQUIPMENT. THE UNIT MUST

BE INSTALLED IN ACCORDANCE WITH

APPLICABLE CODES.

CAUTION

SHIPPING STRAPS ARE UNDER TENSION

AND CAN SNAP BACK WHEN CUT. TAKE

CARE TO AVOID PERSONAL INJURY OR

DAMAGE TO THE UNIT BY STAPLES LEFT

IN THE WALLS OF THE CARTON.

CAUTION

UNIT WEIGHS FROM 468 LBS (212 KG)

TO 1120 LBS (508 KG). FOR SAFE

HANDLING, INSTALLER SHOULD OBTAIN

HELP AS NEEDED AND USE MATERIAL

HANDLING EQUIPMENT TO REMOVE THE

UNIT FROM THE SKID AND MOVE IT TO

ITS PLACE OF INSTALLATION.

The unit arrives completely assembled, except for the TDO valve, ﬂue stack and ﬂue elbow which are usually packed separately and shipped inside the kettle.. The unit is strapped on a skid in a heavy box. Inspect the box carefully for damage. Open the container and check the unit for hidden damage. Report shipping damage or shipment errors to the delivery agent.

Write down the model number, serial number, and installation date for your unit at the top of the Maintenance and Service Log at the back of this manual. Keep the manual on ﬁle and available for operators to use.

To remove the kettle from the box, cut any straps from around the box. Detach the box sides from the skid. Pull the box up off the unit, taking care to avoid damage or injury from any staples left in the box walls. When installation is to begin, cut the straps holding the kettle to the skid, and lift the kettle straight up off the skid. Examine the packing materials to make sure no loose parts are discarded with the materials.

Once the kettle is unpacked, the tangent draw-off valve is easily attached, as shown below. The large nut which attaches the valve to the kettle should be hand tightened only.

Assemble and attach the tangent draw-off

valve after the kettle is unpacked.

6 OM-40GS-KLS

Installation

WARNING

THIS UNIT MUST BE INSTALLED BY

PERSONNEL WHO ARE QUALIFIED TO

WORK WITH ELECTRICITY AND PLUMBING.

IMPROPER INSTALLATION CAN CAUSE

INJURY TO PERSONNEL AND/OR DAMAGE

TO THE EQUIPMENT. THE UNIT MUST

BE INSTALLED IN ACCORDANCE WITH

APPLICABLE CODES.

NOTICE

TO AVOID DAMAGING PARTS OF THE

BURNER SYSTEM UNDERNEATH THE KETTLE,

LIFT THE UNIT ONLY BY THE RING BENEATH

THE OUTER PORTION OF THE BODY.

WARNING

DO NOT ATTACH THE UNIT TO A TYPE “B”

VENT. FAILURE COULD RESULT IN FIRE OR

PROPERTY DAMAGE.

CAUTION

DO NOT USE KETTLE WITHOUT SUPPLIED

FLUESTACK & ELBOW INSTALLED.

FLUE RISER, 17 INCHES HIGH MUST BE

ATTACHED HERE. NOT SUITABLE FOR

CONNECTION TO TYPE B GAS VENT.

CAUTION

DO NOT CONNECT ANY PIPING TO THIS

PRESSURE RELIEF VALVE. IT MUST BE FREE

TO VENT STEAM AS NEEDED. ELBOW SHOULD

POINT DOWN TOWARD FLOOR. IMPROPER

INSTALLATION WILL VOID WARRANTY!

The unit should be installed in a ventilated room for efﬁcient performance. items which may obstruct or restrict the ﬂow of air for combustion and ventilation must be removed. The area directly around the appliance must be cleared of all combustible materials.

1. Installation requires connection with gas and electrical services. See items 8 to 14 for details.

2. To protect the unit from damage, leave it on the shipping pallet until the time of installation. When installation is to begin, cut the straps holding the kettle, and hoist the kettle straight up off the skid.

3. Unit is for use only on non-combustible ﬂoors.

4. Install the unit with a minimum clearance to combustible and non-combustible construction of two inches at the sides and four inches at rear. Also leave enough room for cleaning, maintenance, and service.

5. The ﬂue stack and ﬂue elbow shipped with the kettle is the correct height and shape to give maximum performance. Install the ﬂue stack and ﬂue elbow as shown on the sketch at left.

Unit must be installed under a ventilation hood only. Installation of a ventilating

hood should comply with local codes and/or ANSI/NFPA-96 Latest Edition. Also, local codes may require that the kettle be electrically interlocked to shut off the gas supply and prevent the operation of the unit if the exhaust fan is not operating or if the ﬁre suppression system is activated. Failure to follow these instructions can cause bodily injury and/or property damage.

6. To level the unit, adjust leg length by turning the bullet feet.

7. Make sure the water level is correct in the jacket, by conﬁrming that the level is between the marks on the gauge glass. If the water level is low, follow the instructions under “Jacket Filling” in the “Maintenance” Section of this manual.

DANGER

ELECTRICALLY GROUND THE UNIT

AT THE TERMINAL PROVIDED. FAILURE TO

GROUND UNIT COULD RESULT IN

ELECTROCUTION AND DEATH.

8. To protect personnel from steam coming out of the pressure relief valve, the open end of the elbow at the outlet must be directed down. If it is not, turn the elbow to the correct position.

9. Provide 115 VAC, 60 HZ, 1 PH, 15 AMP electrical service for standard unit. Unit may be equipped for alternate electrical service of 208 VAC or 240 VAC, as ordered. Use 1/2 inch waterproof conduit and waterproof connections. Observe local codes and/or The National Electrical Code in accordance with ANSI/NFPA 70

- latest edition. AN ELECTRICAL GROUND IS REQUIRED. The electrical schematic is located on the inside of the service panel.

In Canada, provide electrical service in accordance with the Canadian Electrical

Code, CSA C22.2 Part 1 and/or local codes.

OM-40GS-KLS 7

Installation

10. The internal gas lines of the unit were cleaned and closed off with a gas cock before the unit was shipped from the factory. Free all external gas lines of lint, dirt, metal chips, sealant, grease, oil, and other contaminants, before you connect the lines to the kettle.

11. Connect the gas cock of the kettle to the gas service main with 3/4 inch IPS line or approved equivalent

12. Installation must conform with local codes, or in the absence of local codes, with the National Fuel Gas Code, ANSI Z 223.1-1988 (or latest edition). The unit should be installed in an adequately ventilated room with a provision for adequate air supply. The best ventilation will utilize a vent hood and exhaust fan with no direct connection between the vent duct and the ﬂue. Do NOT obstruct the ﬂue or vent duct after installation.

In Canada, the installation must conform to the CAN/CGA B149 Installation Codes

for Gas Burning Appliances and Equipment and/or local codes.

13. Adequate space for proper service and operation is required. Do NOT block any air intake spacings to the combustion chamber or obstruct the air ﬂow by piling or stacking anything near the kettle.

14. After the kettle has been connected to the gas supply, all gas line joints must be checked for leaks. DO NOT USE A FLAME TO CHECK FOR LEAKS. A thick soap solution or other suitable leak detector should be employed.

15. PRESSURE TEST WARNING a. Test pressure exceeding 1/2 PSIG (3.45 kPa). During pressure testing of the

gas supply piping system at pressures exceeding 1/2 PSIG, the appliance and its individual shutoff valve must be disconnected from the gas supply piping system.

b. Test pressure equal to or less than 1/2 PSIG (3.45kPa.) During pressure

testing of the gas supply piping system at pressures equal to or less than 1/2 PSIG, the kettle must be isolated from the gas supply piping system closing its individual manual shutoff valve

16. Check the following points to conﬁrm that your AHS kettle has been installed properly. a. Unit installed on non combustible ﬂoor. b. Enough room between the kettle and nearby objects for cleaning and

service. c. Minimum clearance of 2 inches from sides and 4” rear clearance. d. Unit installed under a ventilation hood. e. Kettle level. f. Correct amount of water in the jacket. g. Safety valve outlet pointed down. h. Connected with a waterproof, 115 volt, 15 amp supply of electric power in

accordance with electrical codes. i. Gas lines cleaned before connection. j. Gas connected with 3/4 inch pipe or equivalent. k. Gas line joints checked for leaks. l. No obstruction to air supply or venting.

8 OM-40GS-KLS

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